Methods and systems for acoustically-assisted hydroprocessing at low pressure

ABSTRACT

Hydroprocessing can be performed at low pressure using acoustic energy. For example, hydroprocessing a feedstock having one or more hydrocarbon compounds carried in, or mixed with, a transport gas involves flowing the feedstock through a reaction zone in a reactor that has a bulk pressure less than 68 atm and applying acoustic energy through the reaction zone. The hydrocarbon compounds are chemically reacted with a hydrogen source in the presence of a catalyst, wherein the reacting occurs in the reaction zone.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

This invention was made with United States Government support undercontracts DE-AC0576RLO1830 and HR0011-10-C-0088 to Battelle MemorialInstitute. The Government has certain rights in this invention.

BACKGROUND

Hydroprocessing is important to the production of a wide range ofchemicals and fuels. Hydroprocessing units can have many forms andpurposes within a refinery and are often the most common processing andupgrading units. For example, hydrotreating capacity within a refinerycan comprise over 55% of the total refining capacity. Hydroprocessingcan also be one of the most energy intensive and costly processes offuel and chemical processing facilities. One of the reasons for the highenergy usage and cost, is the high hydrogen pressure, often greater than68 psi, required by traditional techniques.

Generally hydroprocessing is the catalytic conversion and removal oforganic heteroatoms (sulfur, nitrogen, oxygen, and metals) and partial,or full, saturation of aromatic hydrocarbons from various refinerystreams. As the quality of crude oils decrease and the production offuels and chemicals from alternative feedstocks (i.e., biomass, coal,oil shales, tar sands, etc.) increases, the hydroprocessing demandwithin the refinery will have to increase to meet the increasinglystringent environmental regulations placed on fuel specifications andthe growing world-wide demand for diesel fuels. Furthermore as morealternative oils and heavy and extra-heavy oils enter the market, notonly would hydrotreating demands increase for removal of heteroatoms andaromatics, but hydrocracking capacity can be expected to grow toincrease production of gasoline, jet, and diesel fuels from heavierhydrocarbon fractions, such as vacuum gas oils (VGO), petroleum resid(bp>550° C.), and bitumen. Accordingly, a need exists for low pressurehydroprocessing methods and systems.

SUMMARY

This document describes methods and systems for hydroprocessing atrelatively low pressures. In one embodiment, a method forhydroprocessing a feedstock comprising one or more hydrocarbon compoundscarried in, or mixed with, a transport gas is characterized by flowingthe feedstock through a reaction zone in a reactor that has a bulkpressure less than 68 atm and applying acoustic energy into and/orthrough the reaction zone. The method further comprises chemicallyreacting the hydrocarbon compounds with a hydrogen source in thepresence of a catalyst, wherein the reacting occurs in the reactionzone.

As used herein, hydroprocessing can refer to the general processes ofhydrotreating, hydrogenation, and/or hydrocracking of hydrocarbonsources for the production of fuels and chemicals. Hydrotreating canrefer to a collection of processes that include hydrodesulfurization(HDS), hydrodenitrogenation (HDN), hydrodeoxygenation (HDO),hydrodemetalization (HDM), or hydrodehalogenation for the removal ofheteroatoms from hydrocarbon mixtures containing organic heteroatoms.Hydrotreating is a relatively mild hydroprocessing process that aims toselectively hydrogenate and remove the hetroatomic atom(s) from theorganic heteroatoms, without significantly altering the boiling range ofthe final product.

Hydrogenation processes can refer to processes in which the rawhydrocarbons, typically containing aromatics, olefins, or organicheteroatoms are partially or fully saturated with hydrogen to alter thechemical composition and/or properties of the feedstock without completeremoval of the heteroatom or ring-opening or molecular size reduction ofaromatics or polyaromatics. Examples of hydrogenation processes caninclude, but are not limited to aromatic saturation to naphthenes;saturation of alkenes or alkynes to their respective paraffin (ornaphthene); saturation of aldehydes, ketones, epoxides, or organic acidsto alcohols; saturation of nitriles, anilines, or imines to amines;saturation of nitro groups to anilines, amines, or oximes; or relatedhydrogen saturation processes.

Hydrocracking can refer to processes in which hydrogenation and/orhydrotreating occur and are accompanied by cracking or cleavage ofcarbon-carbon bonds within the parent molecule. Examples includehydrocracking of long-chain paraffins to smaller paraffins; ring-openingof naphthenes, saturation of polyaromatics to naphthenes followed byring-opening to generate alkylnaphthene and/or paraffins; dealkylizationof aromatics and/or naphthenes; demethylization (or alkylation) ofiso-parafins to n-paraffins, and other related hydrotreating orhydrogenation processes where the molecular size/weight of the parentmolecule is reduced.

In some embodiments, the acoustic energy induces non-linear acousticeffects (e.g. acoustic streaming and radiation pressure) that, forexample, can enhance mass transfer (e.g. mixing, infiltration,extraction, etc.). Non-linear acoustic energy can be generated usingdevices that provide acoustic frequencies and sound pressure levels thatare together sufficient to induce these effects. In but one example, at20 kHz, sound pressure levels greater than 100 dB can produce non-linearacoustic effects in predominantly gas-based hydroprocessing streams.Calculations of the acoustic Reynolds numbers for 20 kHz at soundpressure levels of 150-170 dB in the gases tested yielded values of ˜1to 200. Reynolds numbers greater than 1 can induce acoustic streaming toenhance mass transfer in gas phase systems. Acoustic streaming is oneexample of a non-linear acoustic effect and is believed to be a primaryacoustic mechanism responsible for enhancing mass and heat transfer.Acoustic streaming, as used herein, can refer to a steady flow fieldsuperimposed upon the oscillatory motion of a sound wave propagating ina fluid. It can occur due to the presence of boundaries or because ofdamping of the wave (attenuation). These steady flows have rotationalcharacter and their velocity increases with sound intensity.

The hydrocarbon compound can comprise solid particulates, liquid fluidand/or vapor. In preferred embodiments, the hydrocarbon compound isoften, though not always, a liquid at room temperature and pressure; itcan be in either the vapor or liquid phase under the reactingconditions. Examples of hydrocarbon compounds can include, but are notlimited to, derivatives or distillate cuts of oils, tars, and/orasphaltenes. Examples of oil, tars, and/or asphaltenes can include, butare not limited to, petroleum, coal-derived oils, biomass-derived oils,oil sands, oil shale, and bitumen sources.

In some embodiments, the reaction zone can have a bulk pressure lessthan 34 atm. In others, the bulk pressure can be less than 17. In yetothers, the bulk pressure can be less than 7 atm. In still others, thebulk pressure can be less than 3 atm. In preferred embodiments, the bulkpressure is approximately equivalent to atmospheric pressure. The liquidhourly space velocity (LHSV) can be greater than 0.1 hr⁻¹.

As described elsewhere herein, the LHSV is defined as the volumetricfeed rate (e.g. units of L/hr) divided by the volume of the reactionzone (e.g. units of L) containing the catalyst. While the weight hourlyspace velocity (WHSV) is defined as the mass feed rate of thehydrocarbon feedstock (e.g. units of kg/hr) divided by the activecatalyst weight (e.g. units of kg). In some embodiments the catalyst isdiluted with inert packing material (e.g. SiC) to aid in the dissipationof heat, in these cases the LHSV is the total volume of the reactionzone that includes both the active catalyst and inert packing material.An approximate equivalent weight hourly space velocity (WHSV) to an LHSVof 0.1 hr⁻¹ is 0.12 hr⁻¹ for a liquid feed density of 0.88 g/ml andactive catalyst packing density of 0.75 g/ml.

Preferably, the average bulk temperature of the reaction zone rangesfrom 120° C. to 450° C. While other temperatures can be suitable,hydroprocessing reactions can benefit from relatively lower temperaturesdue to thermodynamic considerations. For example, above 450° C.,cracking reactions can be predominant. Cracking reactions might bedesirable in certain instances, but often times it is not preferable.

In one embodiment, a method of hydroprocessing a feedstock comprisingone or more hydrocarbon compounds carried in, or mixed with, a transportgas is characterized by flowing the feedstock through a reaction zone ina reactor, wherein the reaction zone has a bulk pressure less than 3atm. The method further comprises applying acoustic energy through thereaction zone, wherein the acoustic energy has frequencies and soundpressure levels sufficient to induce non-linear effects, and chemicallyreacting the hydrocarbon compounds with a hydrogen source in thepresence of a catalyst in the reaction zone.

A variety of hydrogen-containing compounds are suitable for use as ahydrogen source. Examples can include, but are not limited to hydrogen,methane, natural gas, light hydrocarbons (≦C4), and combinationsthereof.

A system for hydroprocessing a feedstock comprising one or morehydrocarbon compounds carried in, or mixed with, a transport gas ischaracterized by an inlet through which feedstock flows to a reactor anda reaction zone in the reactor. The reaction zone comprises a volume inwhich the hydrocarbon compounds react with a hydrogen source in thepresence of a catalyst at a bulk pressure less than 68 atm duringoperation. The system further comprises a transducer coupled to thereactor and configured to impart acoustic energy through the reactionzone.

In some embodiments the reactor can be configured as a trickle bedreactor, a fixed catalytic bed reactor, a fluidized catalytic bedreactor (including ebulating bed reactors), or a moving catalytic bedreactor. The hydrocarbon compounds can be selected from the groupconsisting of solid particulates, liquid fluid, vapor, and combinationsthereof. Preferably, the bulk phase of the feedstock is vapor. Inpreferred embodiments, the bulk pressure in the reaction zone is lessthan, or equal to, 34 atm.

The purpose of the foregoing summary is to enable the United StatesPatent and Trademark Office and the public generally, especially thescientists, engineers, and practitioners in the art who are not familiarwith patent or legal terms or phraseology, to determine quickly from acursory inspection the nature and essence of the technical disclosure ofthe application. The summary is neither intended to define the inventionof the application, which is measured by the claims, nor is it intendedto be limiting as to the scope of the invention in any way.

Various advantages and novel features of the present invention aredescribed herein and will become further readily apparent to thoseskilled in this art from the following description. In the preceding andfollowing descriptions, the various embodiments, including the preferredembodiments, have been shown and described. Included herein is adescription of the best mode contemplated for carrying out theinvention. As will be realized, the invention is capable of modificationin various respects without departing from the invention. Accordingly,the drawings and description of the preferred embodiments set forthhereafter are to be regarded as illustrative in nature, and not asrestrictive.

DESCRIPTION OF DRAWINGS

Embodiments of the invention are described below with reference to thefollowing accompanying drawings.

FIG. 1 is a schematic depicting a tubular system for hydroprocessing afeedstock using acoustic energy according to embodiments of the presentinvention.

FIG. 2 is a schematic depicting a system for hydroprocessing a feedstockusing acoustic energy according to embodiments of the present invention.

FIG. 3 is a graph depicting equilibrium amounts of various compounds asa function of temperature corresponding to operating conditions ofExample 1

FIG. 4 is a gas chromatogram of a product sample obtained from a feedcomprising aromatics after processing according to embodiments of thepresent invention.

FIG. 5 is a plot of the catalytic bed temperature (center of catalyticbed) as a function of time on stream corresponding to example 1

FIG. 6 is a plot of the catalyst bed temperature as a function of timeon stream corresponding to example 2 where not acoustic energy wasapplied for the first 30 minutes on steam or after 135 minutes on stream

FIG. 7 is a plot of the catalyst bed temperature as a function of timeon stream for example 3, where acoustic energy was applied throughoutthe entire duration of testing.

FIG. 8 is a plot of the catalyst bed temperature as a function of timeon stream for example 4, where the conditions are the same as example 3but not acoustic energy was applied throughout the duration of theexperiment.

DETAILED DESCRIPTION

The following description includes the preferred best mode of oneembodiment of the present invention. It will be clear from thisdescription of the invention that the invention is not limited to theseillustrated embodiments but that the invention also includes a varietyof modifications and embodiments thereto. Therefore the presentdescription should be seen as illustrative and not limiting. While theinvention is susceptible of various modifications and alternativeconstructions, it should be understood, that there is no intention tolimit the invention to the specific form disclosed, but, on thecontrary, the invention is to cover all modifications, alternativeconstructions, and equivalents falling within the spirit and scope ofthe invention as defined in the claims.

FIGS. 1-4 show a variety of aspects and embodiments of the presentinvention. Referring first to FIG. 1, the diagram depicts one embodimentof a system 100 for hydroprocessing a feedstock. Acoustic energy isdirected from a transducer 102 to a reaction zone 106 via a waveguide103. The transducer and waveguide can be coupled to a reactor 101 at thereaction zone by a coupling device 104. One example includes, but is notlimited to, a clamp. The reactor in this embodiment is tubular and thereaction zone comprises a volume containing a catalyst 105.

The reactor is configured for vapor phase or mixed vapor and liquidphase operation. In some embodiments, the reactants can comprise a minorfraction of solid particulates and/or liquid fluid carried in, or mixedwith, a transport or reactive gas. The system is configured such thatduring operation, hydrocarbons and a hydrogen source enter the reactortube and pass through the reaction zone, which has a bulk pressure lessthan 68 atm and into which acoustic energy is imparted. Productcollection and/or analysis can occur down stream of the reaction zone.In some embodiments, the reactor can be configured as a fluidizedcatalytic bed reactor or a moving catalytic bed reactor. This is, atleast in part, enabled by the lower pressure operation relative totraditional hydroprocessing systems.

FIG. 2 contains a diagram depicting another embodiment of a system 200.Radiating plates 204 provide acoustic energy from a transducer 202 andthrough a waveguide 203 to the reaction zone 206 of a reactor vessel201. The reaction zone comprises a catalyst load 205. The waveguidesand/or radiating plates can be arranged in a variety of orientationsrelative to the reactor vessel and/or reaction zone. Depending on thetype of reactor (i.e., moving bed, fixed, bed, fluidized bed, etc.), thereactants can enter and products can exit at various positions of thereactor vessel (e.g., top, bottom, side, etc.).

Referring to FIG. 3, a plot summarizes equilibrium amounts oftrans-decalin, cis-decalin, tetralin, and naphthalene as a function oftemperature for a fixed pressure of 1 atm with an 86% H₂ feed, whichcorresponds to the conditions used in Example 1 below. Formation oftoluene and methyl cyclohexane were suppressed to calculate onlyequilibrium naphthalene hydrogenation products of cis-decalin,trans-decalin, and tetralin.

Example 1

Referring to FIG. 4, a gas chromatogram identifies the primarycomponents of a product stream after hydrogenation of a feed comprisingaromatics that include toluene and napthalene in a 3:1 wt:wt ratio oftoluene to naphthalene using acoustic energy according to embodiments ofthe present invention. The product stream includes unreacted feed(toluene and naphthalene), methylcyclohexane as well as tetralin anddecalin (a mixture of both cis and trans isomers), both of which resultfrom the presence of the acoustic energy and are not expected withoutthe acoustic energy. While FIG. 3 indicates the possibility of thepresence of decalin based on equilibrium conditions, in practice theyare almost always absent because of mass transport and kineticlimitations. It is significant that the chromatogram is “clean” and doesnot indicate the presence of other reaction products, within thedetection limits of the GC.

TABLE 1 Sumary of reaction conditions and compositions for a feed streamand four resulting samples Sample Sample Sample Feed 1 2 3 ConditionsTemperature, ° C. 170-215 215-265 265-240 WHSV (hr⁻¹) 5.28 5.28 5.28 H₂,mol % of feed 86 86 86 Acoustic Power, W 300 W 300 W 0 Sampling time,min 30 30 30 temperature rise during 45 50 −25 sampling time, ° C.average Temperature, ° C. 198 232 242 Composition methyl-cyclohexane, wt% 0 39.5 9.2 n.d. Other alkyl naphthalene 0.13 .15 n.d. (C7), wt %Toluene, wt % 74.8 42.78 66.9 77.2 t-decalin, wt % 11.92 6.9 n.d.c-decalin, wt % 0 1.2 1.2 n.d. tetralin, wt % 0 1.93 7.5 7.6naphthalene, wt % 25.2 2.97 4.3 9.01 TOTAL, wt % 100 100.43 96.26 93.82Toluene conversion, % 43.1 7.0 −7.5 naphthalene conversion, % 88.2 82.957 Equilibrium naphthalene 98.4 96.4 90.7 conversion, % Selectivity oftoluene to 97.2 99 −3 methylcyclohexane selectivity of naphthalene to95.8 51 0 decalin (c + t) selectivity of naphthalene to 4.8 49 90tetralin n.d.—not detected/below detection limit

Elaborating on the data shown in FIG. 4, acoustic energy was utilizedaccording to embodiments of the present invention for the vapor phase,low pressure hydrogenation of aromatics to cyclic paraffins. A 3:1mixture of toluene:naphthalene was co-fed with hydrogen into theacoustic reaction zone. Various trials were performed with and withoutacoustic energy at approximately atmospheric pressure. Table 1 providesa summary of the reaction conditions and compositions for the feedstream at three different time intervals (labeled as Sample 1-3) whereinthe experiment conditions between samples 1 and 2 were identical, withthe exception of the catalytic bed temperature increasing due to theexothermic nature of the hydrogenation reactions. For sample 3, acousticenergy was not applied. The temperature during each interval differedbecause the hydrogenation reaction is very exothermic, causing anincrease in temperature as the reaction progressed. FIG. 5 shows thetemperature profile of the catalytic bed as a function of the time onstream with corresponding notation indicating when samples 1-3 werecollected and the time when acoustic energy was turned on and off.

The equilibrium amounts of trans-decalin, cis-decalin, tetralin,toluene, methyl cyclohexane, and naphthalene at variable temperaturesand a fixed pressure of 1 atm with an 86% H₂ feed are provided. Withoutimparting acoustic energy into the reaction zone (see Sample 3),approximately 57% of the naphthalene was converted and only tetralin wasformed. Effectively no toluene was converted and no methyl cyclohexanewas formed. The −7% toluene conversion is believed to be due to theformation of toluene from naphthalene conversion. When acoustic energywas imparted and with temperatures between 170° C. and 215° C. (seeSample 1), approximately 88% of the naphthalene was converted andapproximately 43% of the toluene was converted to methylcyclohexane. Theconverted naphthalene comprised 79% trans decalin, 8% cis decalin, and13% tetralin. At temperatures between 215° C. and 265° C. with acousticenergy (see Sample 2), approximately 83% of the naphthalene wasconverted and approximately 8% of the toluene was converted tomethylcyclohexane. The converted naphthalene comprises 44% transdecalin, 7% cis decalin, and 49% tetralin.

Examples 2

In another example, the same reaction mixture comprising a 3:1 blend oftoluene and naphthalene was co-fed into the acoustic reaction zone,which contained a commercially available hydrogenation catalyst. FIG. 6shows the temperature profile of the catalyst bed throughout the courseof experimentation. For the first 30 minutes on stream, no acousticenergy was applied and the temperature profile of the catalyst bedremains relatively constant at a temperature of 175° C. At a time onstream from 30 minutes through 130 minutes, acoustic energy was appliedto the catalyst bed. Immediately upon turning on the acoustic energy,the bed temperature rapidly increased by ˜20° C. to a temperature of˜195° C. Throughout the 100 minutes when acoustic energy is applied, thecatalyst bed temperature steadily increased to a temperature of 252° C.Once the acoustic energy was turned off at a time on stream of 130minutes the temperature of the catalyst bed steadily decreased. Based onthe exothermic nature of the hydrogenation reactions occurring, theincreasing temperature of the catalyst bed when acoustic energy isapplied to the catalyst bed is a clear indication of hydrogenationactivity at atmospheric pressure. Hydrogenation activity is believed tobe absent when acoustic energy is not applied since the temperature ofthe catalyst bed remains constant or is reduced.

Examples 3

A complex feed mixture can be fed through the system with a compositionshown in Table 2. In the instant example, the experimental conditionswere kept as constant as possible with the exception of the appliedacoustic energy. No acoustic energy was applied and the results arerepresentative of the degree of hydrogenation and desulfurizationachievable under the such a system. FIG. 7 shows the temperature profilefor as measured at the top and the bottom of the bed. When the feed isinitially introduced, there is a slight increase in temperature by ˜3°C. at the top of the bed due to feed preheating at 300° C. However, thetemperature at both the top and bottom of the bed remains relativelyconstant throughout the entire experiment. The lack of temperature riseindicates little to no hydrogenation or desulfurization of thefeedstock, which is confirmed by product analysis shown in Table 3.Table 3 shows that the incoming feed and outcoming product withoutacoustic energy applied has the same (within error) sulfur concentrationand H/C ratio of the oil.

Example 4

Under similar conditions to Example 3, Example 4 applies acoustic energyto the catalytic bed. FIG. 8 shows the temperature rise of the top andbottom of the catalyst bed. When acoustic energy is applied, there is arapid increase in the temperature as measured at the top and bottom ofthe bed, indicating significant hydrogenation activity. Hydrogenationactivity for when acoustic energy is applied to the system is confirmedby both the increase in temperature (even when the heater power for thecatalyst zone is turned off) and by product analysis shown in Table 3.Table 3 shows reduction in sulfur content of the product oil collectedafter 30 minutes and 76 minutes on stream by ˜100% and 96%,respectively, when acoustic energy is applied. Correspondingly the H/Cratio of the oil product is improved from 1.24 to 1.44 and 1.34 after 30minutes and 76 minutes on stream.

TABLE 2 Feed Mixture for Examples 3 and 4 Containing 275 ppm S CompoundWt % in feed Napthalene 7.12 Phenanthrene 1.57 Anthracene 0.95Acenaphthalene 3.15 1-methyl naphthalene 23.65 toluene 30.68 Decane22.35 Benzene 10.40 methylbenzothiophene 0.13

TABLE 3 Summary of Examples 3 and 4 Example 3 Example 4 Example 4 (TOS 0to (TOS 0 to (TOS 30 to FEED 72 mins) 30 mins) 76 mins) CONDITIONS WHSV,hr−1 5.1 5.2 5.2 H2/oil (scf/bbl) 11230 11230 11230 Acoustic Power, W 0650 650 Feed Preheat Temp, ° C. 300 300 300 Wall Temperature 300 260 35Set, ° C. COMPOSITIONS H/C Ratio 1.24 1.25 1.44 1.34 Sulfur Conc., ppmw275 273 BDL 12 mass balance 99.56 94.94 99.54 BDL = below detectionlimit

While a number of embodiments of the present invention have been shownand described, it will be apparent to those skilled in the art that manychanges and modifications may be made without departing from theinvention in its broader aspects. The appended claims, therefore, areintended to cover all such changes and modifications as they fall withinthe true spirit and scope of the invention.

We claim:
 1. A method of hydroprocessing a feedstock comprising one or more hydrocarbon compounds carried in, or mixed with, a transport gas, the method characterized by: Flowing the feedstock through a reaction zone in a reactor, the reaction zone having a bulk pressure less than 68 atm, Applying acoustic energy through the reaction zone; and Chemically reacting the hydrocarbon compounds with a hydrogen source in the presence of a catalyst, said reacting occurring in the reaction zone.
 2. The method of claim 1, wherein the hydrocarbon compounds comprise solid particulates.
 3. The method of claim 1, wherein the hydrocarbon compounds comprise liquid fluid.
 4. The method of claim 1, wherein the hydrocarbon compounds comprise vapor.
 5. The method of claim 1, wherein said applying acoustic energy further comprises inducing non-linear acoustic effects.
 6. The method of claim 1, wherein the reaction zone has a bulk pressure approximately equivalent to atmospheric pressure.
 7. The method of claim 1, wherein the reaction zone has a bulk pressure less than 34 atm.
 8. The method of claim 1, wherein the reaction zone has a bulk pressure less than 17 atm.
 9. The method of claim 1, wherein the reaction zone has a bulk pressure less than 7 atm.
 10. The method of claim 1, wherein the reaction zone has a bulk pressure less than 3 atm.
 11. The method of claim 1, wherein the hydrocarbon compounds comprise derivatives or distillate cuts of oils, tars, or asphaltenes.
 12. The method of claim 11, wherein the oil, tars, or asphaltenes comprise petroleum, coal-derived oils, biomass-derived oils, oil sands, oils shale.
 13. The method of claim 1, wherein the hydrogen source is selected from the group consisting of hydrogen, methane, natural gas, light hydrocarbons (≦C4), and combinations thereof.
 14. The method of claim 1, having a liquid hourly space velocity (LHSV) greater than 0.1 hr⁻¹.
 15. The method of claim 1, wherein the reaction zone has a bulk temperature from 120° C. to 450° C.
 16. The method of claim 1, wherein said reacting comprises a reaction selected from the group consisting of hydrogenation, hydrocracking, hydrodesulfurization, hydrodenitrogenation, hydrodeoxygenation, hydrodemetalization, and combinations thereof.
 17. A method of hydroprocessing a feedstock comprising one or more hydrocarbon compounds carried in or mixed with a transport gas, the method characterized by: Flowing the feedstock through a reaction zone in a reactor, the reaction zone having a bulk pressure less than 3 atm, Applying acoustic energy through the reaction zone, the acoustic energy having frequencies and sound pressure levels sufficient to induce non-linear effects; and Chemically reacting the hydrocarbon compounds with a hydrogen source in the presence of a catalyst, said reacting occurring in the reaction zone.
 18. A system for hydroprocessing a feedstock comprising one or more hydrocarbon compounds carried in, or mixed with, a transport gas, the system characterized by: An inlet through which feedstock flows to a reactor; A reaction zone in the reactor, the reaction zone comprising a volume in which the hydrocarbon compounds react with a hydrogen source in the presence of a catalyst at a bulk pressure less than 68 atm during operation; and A transducer coupled to the reactor and configured to impart acoustic energy through the reaction zone.
 19. The system of claim 18, wherein the reactor is selected from the group consisting of trickle bed reactors, fixed catalytic bed reactors, fluidized catalytic bed reactors, and moving catalytic bed reactors.
 20. The system of claim 18, wherein the hydrocarbon compounds are selected from the group consisting of solid particulates, liquid fluid, vapor, and combinations thereof.
 21. The system of claim 18, wherein the acoustic energy has frequencies and sound pressure levels sufficient to induce non-linear effects.
 22. The system of claim 18, wherein the reaction zone has a bulk pressure less than 34 atm. 